for Dozing, Gen 3.0 Remote Control Operator Console with RFID Operator Console Caterpillar

Operator Console

Illustration 1	g03673565
Operator console (1) Engine deceleration lever (2) Service brake lever (3) Status display (4) Implement select switch (5) High-idle engine speed select dial (6) Blade float select button (7) Auto blade assist mode select button (8) Blade pitch / ripper auto functions control knob (9) Implements control (10) Implement lockout switch (11) Machine power / engine crank switch (12) Parking brake switch (13) Steering / direction control (14) Gear shift up / down knob (15) Avoidance zone LED (16) Parking brake LED (17) Software stop LED (18) Fire suppression switch (if equipped) (19) Active fault LED (20) Implement lockout LED (21) Battery / antenna LED

Illustration 2	g03673583
Left side of operator console (22) Engine high / low idle button (23) Display select button

Illustration 3	g03673584
Right side of operator console (24) Operator console power-on button (25) Horn button (26) Operator console power off / commanded stop switch (27) Grade control enable button (28) Machine light button (29) RFID chip slot

Illustration 4	g03673588
Steering / direction control (13) Steering / direction control (14) Gear shift up / down knob

The Steering / Directional control is used to steer the machine and change direction (forward, neutral, or reverse). The top of the control is the Gear Shift Up / Down knob. The Gear Shift Up / Down knob is used to shift the transmission up or down. When the Steering / Directional control is being used to move the machine and released to center the transmission will automatically shift to neutral.

Illustration 5	g03673589
Implement control (8) Blade pitch / ripper auto functions control knob (9) Implements control

The Blade Pitch / Ripper Auto Functions Control knob is used to tilt the blade, raise the ripper or AutoStow the ripper. The Implements control is used to operate the implements.

Illustration 6	g06244593
Operator console access card

The Operator Console Access Card is used to power on the Operator Console at Console startup.

Battery and Charger

Illustration 7	g06228320
Battery charger

Illustration 8	g06245268
Battery

Illustration 9	g03673059
Bottom of operator console (2) Battery location (3) RFID chip slot location

Illustration 10	g06231969
On-Board Transceiver (6) Power on LED (7) RF interruption LED (8) Si1 LED (9) Si2 LED (10) Feedback LED (11) CAN LED

The On-Board transceiver is used to communicate between the operator console and the remote control electronics that are on the machine. Both transceiver and console must share frequency communication protocols and will be offered with either with a 900 MHz or 2.4 GHz. Each transceiver will be shipped from factory with a unique Radio Frequency Identification (RFID) chip to pair to the console. The transceiver is located on the Roof. The Antenna is connected to the transceiver.

Power On LED (6)– Illuminates yellow when receiver is powered.

RF Interruption LED (7)– Illuminates red when radio connection is interrupted.

Si1 LED (8)– Illuminates solid green on radio connection. Radio connection and valid e-stop condition. Commands available under Si1 are non-safety relevant. (Example: Lights, Horn, and soon.)

Si2 LED (9)– Illuminates blink green on driven command. Active Si1 status plus at least one telegram with without SI2-condition and inactive SI2 commands have been received (enforced zero position) after the SI1 status has been reached and a valid telegram with Si2 and Si2 associated command. Commands involve safety-related machine functions. Only lights when Si2 is active. (Example: Engine Start, Track Drive, and so on.) Si2 should light only when an Si2 command is active.

Feedback LED (10)– Will always blink. LED blinks with each telegram from the receiver to the console. (Feedback of machine data on console screen.

CAN LED (11)– Flash green with CAN communication. Since the system is in constant communication, this LED will constantly be blinking green.

The battery is inserted into the bottom of the operator console.

Radio Frequency Identification (RFID) Chip

Illustration 11	g06245297
RFID chip

The Console is modular and can be used with multiple receivers. The On-Board Receiver is shipped with a Radio Frequency Identification (RFID) chip that is matched to the receiver. The RFID chip is matched specifically to the receiver the chip is shipped with. The RFID chip cannot be used to operate any other machines except for the one with the matched receiver mounted. The serial number listed on the RFID chip matches that of the matched receiver. To use the console with another receiver, the Radio Frequency Identification (RFID) Chip must be removed. A new RFID chip (from the pair receiver) should be installed. The RFID chip can be removed from the console and put into a spare console to operate the machine if the need arises.

Note: The paired RFID chip needs storage in a safe place. The replacement service part is ordered as a Kit and will include the RFID chip and receiver. The replacement service kit does not include the Antenna. the RFID chip and receiver are not sold separately.

The Console will not operate without the proper RFID chip.

Automatic Frequency Selection (AFS)

Using 900MHz, Automatic Frequency Selection (AFS) will check if the present radio channel is free. If the radio channel is occupied, the system automatically finds and saves a free radio channel. If the radio channel currently in use is occupied by another radio control system, you must switch the transmitter off and on again to allow AFS to switch to a free radio channel. If AFS is to perform optimally, all the other radio systems in the immediate working environment (such as the factory hall or building site) should be switched on before starting to use the radio system for the first time. Switching all the other radio systems ON before using the system allows AFS to detect automatically which radio channels are already being used in the working area and to choose a suitable free channel for use. In addition, when switching on the radio system for the first time, the user should make sure that the distance from the radio receiver and from the machine is a realistic reflection of the working situation.

Frequency Hopping Spread Spectrum

2.4 GHz technology works with automatic frequency coordination and thus ensures interruption -free working in areas with many radio users. Manual frequency coordination is not necessary. With the worldwide frequency band, 2.4 GHz technology can be used all over the world.

Low Battery Warning

Battery capacity indicator will show no more bars remaining and will change color to red when approximately 10 percent capacity remains. With a new battery this condition means approximately 2.5 hours of operational time remains.

When approximately 4 minutes of operational time remain, a critical battery alarm activates consisting of:

• The battery LED flashing red

• An audible alarm

• The LCD displaying "Low Battery Warning" across the entire screen

Normal LCD functionality will be lost but the controls will still function now.

Manual Operation

When the Manual/Remote Mode switch on the Ground Level Service Center (GLSC) is in the MANUAL position, the Command for dozing system is powered down. All relays are in an inactive (normally closed) state. In this state the machine acts as if the Command for dozing system is not installed on the machine.

Carry Case and Equipment

Illustration 12	g02947336
Carry case

The carry case is provided to be a safe storage and transportation tool for the operator console and related components.

In addition to the operator console, storage space is provided for the receiver, antenna, batteries and charger, shoulder harness, and all service publications.

Remote Operation

Note: The following information describes what occurs onboard the machine when the Manual/Remote Mode switch on the GLSC is placed in the Remote position.

The System Master (RCM) energizes the following relays by switching contact 85 of the relays to ground:

• Cab Key Disable

• Parking Brake Switch Disable

• Implement Lockout Switch Bypass

• Mode Select

• RC Auxiliary

This action will bypass, on the machine the following:

• Key Switch

• Parking Brake Switch

• Implement Lockout Switch

The Command for dozing system can now override each of these functions.

The mode select relay puts the ECMs of the machine into RC Mode. The RC Auxiliary relay supplies power to the indication system mounted on the ROPS. All 5 of these relays remain energized until the machine is put back into "Manual Mode" via the Manual/Remote Mode switch on the Ground Level Service Center (GLSC) or into manual override mode via the switch in the cab of the machine.

Illustration 13	g03795329

The "Parking Brake Switch Disable" relay is used to disable parking brake switch of the machine. Disabling this switch must be done in order for the Command System to be able to take over control of both states of the parking brake solenoid. Due to the importance of this feature, the parking brake solenoid is controlled redundantly via the switch and the power train ECM. Refer to Illustration 13 . This relay not only disconnects the machine parking brake switch from the solenoid circuit, but also redirects that solenoid to the RCM to be driven redundantly (with the power train ECM).

Illustration 14	g03795339

The "Implement Lockout Switch Bypass" relay is used to bypass/disable the machine implement lockout switch. Disabling the switch must be done in order for the Command System to be able to take over control of both states of the implement lockout solenoid.

The RCM also energizes the following relay by switching contact 85 of the relay to ground. The "Mode Select" relay energizes, contact 47 of the power train ECM and contact 62 of the implement ECM, which modifies the ECM harness codes enabling Remote Control operation. These relays remain energized while the Command System is enabled.

Indicator Control Electronic Control Module

Blue remote status indicators, mounted on the ROPS, are turned on solid when the System Master powers up.

Note: Now the System Master is powered. The Machine ECMs will be powered via the Operator Console.

Establishing a Link

The Operator Console requires that the operator or service technician perform the initialization procedure on the Operator Console to establish the communication link with the onboard RCM.

Operator Console Pre Start Up Checks

1. Take note of the area around the machine and walk to the side of the machine about 15 m (50 ft) away.

2. Confirm that the Commanded Stop switch (25) on the remote console is turned off, turn the switch in the clockwise direction to disengage.

3. Turn the following switches to the default position.

   • "Implement Lockout" (10) ON

   • "Parking Brake" (12) ON

   • "Machine Power / Engine Crank" (11) OFF

   • "Implement Control" (9) CENTER

   • "Steering / Direction Control" (13) CENTER

   Note: The default positions of these switches are noted by yellow icons.

   Note: The console will link up to the receiver. However, no switches, buttons, or joysticks will be enabled until all switches are in the default state and all controls are neutralized.

4. Make sure that the operator console is upright.

   Note: The operator console has a built-in inclinometer which prevents operation when the console is tilted past 60 degrees in any direction.

Scanning Command for Dozing Operator Console Access Card for Start Up

1. Ensure that the Parking Brake, the Implement Lockout, and the Machine Power switches are in the default states, and all controls are neutralized.

2. Release Operator Console Power Off / Commanded Stop switch (26).

3. Press Operator Console Power On button (24) to power up the console.

4. Within 8 seconds, scan the Operator Console Access Card on the front-right corner of the Operator Console where the indicator label is.

   Note: If the Access Card is not scanned within 8 seconds, the Operator Console will power off, and the procedure will require repeated.

Operator Console Start Up

1. The Software Stop LED (17) will remain on. If the communication link is successfully established with the receiver, the status display LCD will show an active parameter. If an active parameter is not shown, the status display LCD will be blank. This signifies that there is no data. When this occurs, check all connections between the onboard receiver and the remote control ECM.

2. Place the Machine Power / Engine Crank switch (11) on the operator console to the ON (center) position.

3. Hold the horn button (25) on the operator console until the machines horn stops sounding (approximately 3 seconds).

   Note: At least once a day the action alarm on the Operator Console should be checked to be sure that the alarm is functional. Refer to the Operation and Maintenance Manual, SEBU8835, "Console Action Alarm Check" for more information.

4. Release the Horn button (25).

   The horn will sound and machine lights will flash two times.

   Note: The Software Stop LED (17) will blink with every horn sound from the machine. The Software Stop LED (17) will turn off following the second horn sound.

5. Push the Machine Power / Engine Crank switch (11) towards the crank icon and hold the switch in the crank position until the engine starts. After the engine starts release the switch.

   Note: The blue indicator light will now be blinking twice per second in a heartbeat (double beat) pattern.

Powering the Machine

Machine power and engine start are controlled via the Machine Power/ Engine Crank switch (11) on the operator console. This switch has the following three positions:

• OFF Position (Machine Power)

• ON Position (Machine Power)

• Engine Start Position (momentary)

The OFF position and ON position of the switch are maintained positions. The Engine Start position is a momentary position, springing back to the ON position. "Machine Power" relay is energized when this switch is in the ON position and the RC System is not in the Commanded Stop state.

Issues that may cause an "Commanded Stop State" include:

• Operator Console Power Off / Commanded Stop switch being pressed

• Loss of receiver link

• A non-recoverable system condition

Illustration 15	g03817673

Once the Machine Power/ Engine Crank Switch (11) on the operator console is moved to the ON position (middle), machine dash, and Advisor should power up and the Alert Audible Alarm in the cab should sound for one second.

Note: If a fault is present, the Active Fault LED would be seen, and Operator Console audible alarm will be heard.

Activating Remote Control

Now the machine has been powered, the operator will need to press the Horn button (25) on the operator console to activate RC. This action is done until the machines horn stops sounding (approximately 3 seconds).

Once the operator releases the horn button (25), the following will occur:

• The machine horn will sound two times and the machine lights will flash twice.

• The "Remote Active" LED and the "Software Stop" LED will continue to blink while the horn is sounding.

• The "Remote Active" LED will remain illuminated and the "Software Stop" LED will turn off following the second sounding of the horn (assuming RC is activated successfully).

The horn is a purely electrical feature on the machine and is controlled via a pushbutton switch in the cab of the machine. The horn is controlled via a pushbutton switch on the RC console while in RC Mode.

Horn control is wired such that, either the switch in the cab or the button on the remote control console can actuate the horn. The horn will be actuated if either of these operator interfaces are actuated. So, if the horn switch on the machine is ON, then the RC System cannot turn the horn OFF.

Note: This way, a person in the cab of the machine can audibly alert the remote operator that someone is in the cab of the machine

The horn is controlled via the "Horn" relay. The Remote Control ECM energizes the "Horn" relay by switching contact 85 of the relay to ground.

While activating RC, once the operator releases the horn button (25), the following will occur:

• The machine horn will sound two times and the machine lights will flash twice.

• The "Remote Active" LED and the "Software Stop" LED will continue to blink while the horn is sounding.

• The "Remote Active" LED will remain illuminated and the "Software Stop" LED will turn off following the second sounding of the horn and the blue indicator will change from solid blue on to flashing in a double “heart beat” pattern. (assuming RC is activated successfully).

Cranking the Engine

Push the Machine Power / Engine Crank switch forward to the engine crank position until the engine starts. Then, release the switch.

The Remote Control ECM energizes the "Engine Start" relay by switching contact 85 of the relay to ground when the Machine Power / Engine Crank Switch on the Operator Console is placed in the Engine Start position.

Note: The "Machine Power" relay remains energized while the "Engine Start" relay is energized.

Operator Console Controls and Machine Response

Operator Console Commanded Stop Switch

Illustration 16	g03817677
Operator console commanded stop switch

The Operator Console Commanded Stop Switch is used to shut down the electronic controls of the machine in an emergency. The Shutdown command causes the internal "Commanded Stop Relay" in the Remote Control Primary receiver to de-energize and remove power from the engine.

Note: An event is logged by the Remote Control ECM when the Operator Console Commanded Stop Switch is used to shut down the machine.

Operator Console Internal Tilt Switch

The Operator Console has an internal tilt switch that shuts down the machine. Shutdown is done when the console is tilted at an angle of 60 degrees from horizontal.

Note: This feature prevents machine operation if the operator falls down.

Implement Controls

The Implement Controls of the Command System are listed here:

• Implement Control / Blade Control (raise/lower, tilt left/right, pitch forward/back, float)

• Single/Dual Tilt Blade Mode (assuming dual tilt is installed on machine)

• Auto Blade Assist Mode (ABA)

• AutoCarry/AutoRip if equipped (JEL, ; JNS, ; AMA, and ; MDG only)

• Implement Control / Ripper Control (raise/lower, in/out, auto stow) (if enabled)

• Implement Select Switch

• Implement Lockout

The implement commands from the Operator Console are sent to the Remote Control ECM via the Remote Control receiver. The Remote Control ECM then relays the implement commands to the machine Implement ECM via the machine CAN circuit. The system utilizes the existing implement system of the machine to control the implements.

Power Train Controls

The Power Train Controls of the Command System are listed here:

• Steer/Direction Control (Direction (FNR), and Steering)

• Gear Selection (1 or 2)

• Bi-directional Autoshift / Enhanced Autoshift if enabled (JEL, ; JNS, ; AMA, and ; MDG only)

• AutoKickdown

• Service Brake

• Parking Brake

The Power Train commands from the Operator Console are sent to the Remote Control ECM via the Remote Control receiver. The Remote Control ECM then relays the power train commands to the machine power train ECM via the machine CAN circuit. The system utilizes the existing power train controls of the machine to control the power train.

Engine Controls

The Engine Controls of the Command System are listed here:

• Engine Start

• Engine Speed (via high/low toggle as well as maximum engine speed dial)

• Engine Shutdown

• Engine Deceleration

The engine commands are sent from the Operator Console to the Remote Control ECM via the Remote Control receiver. The Remote Control ECM then relays the engine commands to the machine engine ECM via the machine CAN circuit.

Light Switch

The machine has eight sets of lights and, therefore, eight lighting circuits. Only seven of these circuits are controlled by the Command System. The Command System does not control the on-board backlighting (of switches and instruments). Of those seven, only six of the circuits are purely electrical and, therefore, require relays to be controlled. The fender lights are controlled via the power train ECM, which reads a switch and controls the lights via an on-board relay controlled via one of the power train ECM output drivers.

Illustration 17	g02458761

The lights can be controlled either from the switches on the machine or with the Command System. If either the machine switch controlling a lighting circuit is ON or the Operator Console light switch is turning a set of lights ON, that set of lights will be ON. So, if a switch on the machine controlling a lighting circuit is ON, then the Command System cannot turn that circuit OFF.

Note: This wiring configuration is done so that a person in the cab of the machine can visually alert the remote operator that someone is in the cab of the machine.

Note: This light control is also useful if an operator wants to select only certain sets of lights during night operation

The RC System controls the lights via one switch on the RC console. When this switch is sensed ON, the Command system energizes all six of the lighting relays. These relays are "Cylinder Lights", "Ripper Lights", "Forward ROPS 1", "Forward ROPS 2", "Rear ROPS 1", and "Rear ROPS 2". The two Forward ROPS relays (1 & 2) are energized via one output of the Remote Control ECM. Energizing is also true for the two Rear ROPS relays (1 & 2).

Note: This information is only useful because both relays would have to fail for there to be a raised diagnostic.

Fire Suppression

Since AVSpare does not provide Fire Suppression Systems to customers, the Command System provides a means to electrically or electronically actuate a fire suppression system. Because most Fire Suppression Systems are costly to recharge and clean up after once activated, Fire Suppression is activated by a guarded toggle switch on the Operator Console. The guard must be lifted prior to actuating the 2-position maintained Fire Suppression switch. Fire suppression is actuated via a relay. The RC System only controls the relay coil. The common, NC, and NO pins are provided to the customer via a 3-pin connector in the RC System harness.

Illustration 18	g06049706

When the Fire Suppression Switch is turned to the ON position, the Operator Console sends the command to the Remote ECM via the Remote Control receiver and then energizes the coil of the fire suppression relay. The relay is in NC state when the relay is not activated. Once the coil is energized, the state of the relay changes to NO.